Composition comprising a polyisocyanate reaction product and a polysulfide polymer



2 Claims. (Ci. 26il--42) This invention relates to organic chemical compositions and relates more particularly to resinous products or compositions useful as coatings, sealants, films, impregnating materials, adhesives, etc.

This is a division of copending application Serial Numher 455,766 filed September 13, 1954, now Patent No. 2,929,794.

it is an object of the invention to provide resins or resinous products that polymerize and air cure at room temperatures to form tough, fi6Xlbl,16SlllI1t coatings, films, caulkings, sealants, and the like. These resins or resinous materials may be used as one hundred percent solids content resins or in resin-solvent combinations and may be applied in practically any selected manner to metals, wood, plastics, paper, and the like, to constitute protective coatings, may be used as impregnating materials for fabrics, screens, papers, and other porous and semi-porous materials, may be used as moisture proof coatings for moisture sensitive materials of various kinds, and may be applied to mandrels for subsequent removal therefrom in the cured condition as plastic films. The adhesion of the resinous material to fabrics, wood and porous surfaces is excellent and they may be employed to form transparent or semi-transparent elastic coatings or, if desired, may incorporate pigments, plasticizers, and other modifiers, fillers, and the like. Appropriate or required variations in the physical characteristics of the resultant coatings, films, etc. such as the toughness, elasticity, temperature resistance, are obtained by selection of the resin components and the resins may be prepared to best adapt them for the intended mode of application such as brushing, dipping, spraying, blading, rolling, and the like.

Another object of our invention is to provide resin compositions useful as elastomeric sealing and caulking materials that are resistant to water, oils, aromatic-aliphatic fuels, etc., that preserve excellent adhesion to most solids and that retain their flexibility and elasticity throughout a wide temperature range. The sealants of the invention air cure at room temperature to tough, rubbery adherent void free fillets, films, or bodies, that are highly water, oil and hydrocarbon fuel resistant, and that remain flexible, elastic and crack free over a wide temperature range. We have found that the cure of these sealants is materially accelerated by the use or incorporation of a special two-part catalyst system. The applied sealants will cure in thick or large sections without the formation of voids while retaining their flexible, elasticity, adhesion and resistance to water, oils, and the like.

It is a further object of the invention to provide resinous products or materials which, when used as coatings, films, etc. will air cure in thin layers of less than one-half mil and up to 100 mils thickness by reason of the structure of the resins which enables them to react with the moisture of the air to polymerize into tough, resilient, adherent, elastomeric coatings and When said resinous materials are used as sealants, putties, etc. this atmosphericmoisture curing reaction materially assists the catalyst system in eltecting the cure. In the case of the thin or States Patent relatively thin films, coatings etc. the air cure is efiective at room temperature and a relative humidity of from 20 to 98% by reason of said reaction and without the use of catalysts, oxygen, or drier activators. However, where the resins are used as or incorporated in sealants, caulking compounds, putties, and the like, it is desirable to expedite or accelerate the cure by means of a catalyst system aided by the atmospheric moisture reaction cure.

The resinous materials of the invention are useful as adhesives, interlayer materials, special electrically conductive layers or coatings, etc. and where we refer herein to coatings and sealants, other uses and applications are to be understood as comprehended by such terms.

The resinous products or resinous compositions of the invention are fluid derived polymers or copolymers of polyisocyanates, polyisothiocyanates, and their blends with polylabile hydrogen-containing compounds and contain reacted or partially reacted polyisocyanates, polyisothiocyanates, and their blends. Typical of the resins which have chemical compositions suitable for modification by the po-lyisocyanate or polyisothiocyanate resinous reaction products of this invention are Thiokols, polyesters, polyamides, polyureas, polyesteramides, polyurethanes and blends or combinations of such resins. Although the resinous compounds or resins are synthesized in accordance with the known rules of polymer formation, the selection of their components and the manner and sequence of combining their components have been found to be productive of unusual characteristics, particularly well suiting them for use as films, coatings, sealants, or components of such products. A characteristic requirement for the isocyanate-containing resins of this invention is that they include or consist of polymer chains or systems of polymer chains containing active or functional chemical groupings at given or specified intervals by means of which the chains or chain systems are caused to be bound one to the other. The selected molecular units are caused to conform to typical patterns. The selected molecular components are representative of, but are not exclusive of, applicable units known in the art. The general type of polymer basically suitable is an anchored linear polymer chain containing reactive functional groups at specified intervals. The resins or resinous products of the invention are the result of the chemical reaction of polyisocyanates or polyisothiocyanates, or

, their blends, of from 15 to 85 mol percent of either comp nent. with polylabile hydrogen type compounds such as acids, alcohols, silicols, enols, amines, imines, amidines, amides, ureas, thioureas, thioamides, mercaptans, aldols, aminoalcohols, ureides, thiolic acids, hydro oxamic acids, hydrazines, etc.

The components of the resinous materials of the invention are not all permitted to compete one with the other simultaneously for the active or functional groups of a present coreactant molecule. In the preparation of the resins it is preferred that an initial reaction occur in accordance with a given order of component addition to obtain reproducible, controllable and determined results. A preferred order of reaction of the components in preparing the resin is: First, a reaction between (1) a diisocyanate, polyisocyanate, polyisothiocyanate, or blends thereof, and (2) diols, such as polyglycols, linear aliphatic glycols, or substituted or unsubstituted modifications and blends thereof. The diols may be replaced to an extent up to 40% by weight of nitrogen base resinous compositions having a molecular weight of between 500 and l0,- 000, these nitrogen base resinous compositions being the reaction products of dibasic alkyl carboxylic acids with amino alcohols and alkylamines, and the self esterified reaction products of linear alkyl amino acids, or by polvmeric polysulfides within the molecular weight range of from 200 to 10,000, the latter being known commercially as Thiokol base compounds. These Thiolrol compounds are preferably the reaction products of dihaloalkylformals, sodium polysulfide and trihaloalkyls such as reaction products of dichloroethylformal, sodium polysuliide and trichloropropane. As will be described later in more detail, the resins or resinous compositions of the invention, which include the Tliiokols as components thereof, are particularly well suited for use as or for preparing sealant materials, putties, and the like.

The second stage in the preparation of the resin is the addition to the initial reaction product of a bifunctional acid such as a linear hydroxy acid, a dicarboxylic acid, an amino acid, or unsaturated, substituted modifications or blends of the same and water, the resultant mixture reacting to form what may be termed an intermediate. The third stage in the preparation or reaction of the resin is the reaction between the pro-reticulated polymers resul ing from the first and second stages of reaction above described and a reticulating agent which is a trifunctional molecule containing alcohol, carboxylic acid, amine or mercaptan groups, or mixtures of the same. The preparation or reaction of a resin is concluded when the resultant resin reaches an amine equivalent of from 150 to 1,000, an amine equivalent value of approximately 500 being preferred. In describing the preparation or reaction of the resin the reticulating agents referred to are comprised of a molecule containing more than two functional groups comprising isocyanates, isothiocyanates and the above mentioned polylabile hydrogen compounds.

The following table indicates the proportion limitations or ranges of the components employed in the preparation of the above described resin, the proportions being given in mol percent, the minimum and maximum percentages for the individual components being the quantities usable in its optimum formula to yield 100 mol percent.

Min Opt, Max,

M01 Mols, M01 Mols, M01 Mols, ler- Min. Pcr- Opt. Pcr- Max. cent cent cont diol alcohol 2. 5 A 0. 3 1 23. 5 3 bifunctioual acid. 2.5 9.3 1 23.5 3 retieulatiug agent 1.08 -l. 65 16.3 2 diisocyanate 64. 5 5 74. 43 8 84. 5 15 water 0.59 As 2. 32 8 7 1 1 The diisocyauate may be replaced by a blend of polyisocyauates and polyisothiocyanates.

The isocyanate component of the resins of the inventron are polyisocyanates and polyisothiocyanates of the general formula:

in which R is an intervening organic group or groups.

Examples of the suitable diisocyanates and diisothiocyanates are as follows:

Xylene diisocyanate 2-4 cyclohexylene diisocyanate 1,1 dibutyl ether diisocyanate 1,6 cyclopentane diisocyanate 2,5 indene diisocyanate 2,5 dicnloro octane diisocyanate Examples of isocyanates and isothiocyanates having a functionality greater than 2 that may be used as reticulating agents in the preparation of the resins of the Invention include:

1,3,5 phenyl triisocyanate 2,4,6 toluene triisocyanate 1,3,6 hexamethylene triisocyanate 1,3,5 naphthalene triisocyanate Triphenyl methane triisocyanate 1,3,5 phenyl triisothiocyanate 2,4,6 toluene triisothiocyanate 1,3,6 hexamethylene triisot'niocyanate 1,3,5 naphthalene triisothiocyanate Triphenyl methane triisothiocyanate.

Suitable polyfunctional alcohols from which the polyurethane or polythiouretliane intermediates may be pre pared include aliphatic diols of linear structure represented as follows:

Substitution of halide, nitro, amine, kcto or ether groups may occur as parts of the R groups above. Urisaturation or the occurrence of ethylenic or acetylenic linkages in the structure is also permissible.

Where polyhydric alcohols are employed as reticulating agents in the preparation of the resins of the invention it is required that three or more functional hydroxy groups be present. These structures are analogous to those of the diols except that methylene hydrogen atoms are replaced by hydroxy groups. The aliphatic p lyhydric alcohols employed may contain aromatic, alicyclic or heterocyclic groups provided that no more than one is employed per molecule unit.

Polyols such as dihydric alcohols, glycols, polyglycols, and blends of the same are suitable as reactant diols in the preparation of the resins of the invention. it is preferred to use glycols or low molecular weight diols (molecular Weight not greater than 400) in combination with polyglycols such as polypro ylene glycol, P 3 ethylene glycol, and polybutylene glycol having an aver age molecular weight in the range between 400 and 10,000. in blends of the low molecular weight glycol and polyglycols there should be no more than 20 mol percent of the glycol. Typical examples of the polyols which we prefer to employ as reactants with the polyisocyanates and polyisothiocyanates and their blends are:

Polyhydric alcohols having a functionality greater than 2 may be employed as reticulating agents for the resins of the invention. Such polyhydric alcohols include glycerol, polyglycerol, diglycerol, mannitol, sorbitol, petite-- erythritol, dipentaerythritol, 1-2-6 hexanetriol, 1-2-4 butanetnol. If polyhydric alcohols having a functionality greater than 3 are employed they must housed inv blends with triols in proportions where the triol is not less than 50 mol percent of the blend employed as areticulating agent.

Polyfunctional alkylorganic acids suitable for reaction during the second stage of the preparation of the resins are substituted, unsubstituted, saturated or unsaturated and may include polycarboxylic types having a molecular weight range of from 90 to 800 and polyhydroxy carboxylic types having a molecular weight range of from 75 to 800. Suitable carboxylic types of such acids include rnalonic, succinic, sebacic, adipic, pirnelic and azelaic while suitable polyhydroxy carboxylic acids include l-hydroxy decanoic acid, ricinoleic acid and glycolic acid. The use of polyiunctional acids as reticulating agents requires that three or more functional groups with regard to labile hydrogen be present in their respective molecules. Typical examples include tartaric acid; 1,2 dihydroxy 1, butanoic acid; butane tetracarboxylic acid; 1,2,6 hexane trioic acid; l-hydroxy, 3-arnino, S-pentanoic acid; and ethylene diarnine tetra-acetic acid.

The following formulationsare typical preferred examples of the resins of the invention. In these several examples the constituents or ingredients are in mol percentages.

RESIN 1 [Amine equivalent 500-700] M01 percent [Amine equivalent 500-600] 2,4 toluene diisocyanate (60-90 mol percent) 2,6 toluene diisocyanate Hydroxy decanoic acid 9.30 Water (range 2-4 mol percent) 2.32 Trirnethylol propane 4.65 Polypropylene glycol (avg. mol. wt. 10,000) 9.3.0

RESIN 3 [Amine equivalent 450-500] 2,4 toluene diisocyanate (60-90 mol percent) Hexainethylene diisocyanate 7443 Sebacic acid 9.30 Hexarnethylene glycol (5-15 mol percent) 9 Polypropylene glycol 3000 Water 2.32 1-2-6 hexane triol (range 1-8 mol percent) 4.65

RESIN 4 [Amine equivalent 400-500] 2,4 phenyldiisocyanate (70-80 mol percent) 74 43 1,4 phenyldiisocyanate Polyethylene glycol (avg. mol. wt. 600) 9.30 Pentaerythritol 4 65 1,2,6 hexanetriol (50-90 mol percent) Ricinoleic acid (50-90 rnol percent) Lactic acid Water 2.32

RESIN 5 [Amine equivalent 400-600] Meta toluene diisocyanate 74 43 Dianisidine diisocyanate (1-5 mol percent) Polypropylene glycol (avg. mol. wt. 3000) 9 30 Dihydroxydiethylsilane (1-5 mol percent) Ricinoleic acid 9 30 Hydroxyacetic acid (6-18 mol percent) Glycerol 4.65 Water 2.32

-p,p' Diphenyldiisocyanate (1-5 mol percent) a RESIN 6 [Amine equivalent 500-000] M01 percent 2,6'rneta toluene diisocyanate Butynediol (1-15 mol percent) 30 Polypropylene glycol (avg. mol. wt. 2000) Alphahydroxy decanoic acid 9.30 Mannitol 4.65 Water 2.32

RESIN 7 [Amine equivalent 300-600] Diethylsilane diisocyanate (1-10 mol percent) 74 43 2-4 rneta toluene diisocyanate 2,4 dichloro 1,4 butanediol Polypropylene glycol (avg. mol. wt. 400) 9.30

(50-90 mol percent) 1,2, 6 hexanetriol 4.65 Adipic acid 9 30 Butane tetracarbolylic acid (2-8 mol percent) Water 2.32

RESIN 8 [Amine equivalent 400-600] 2,4 meta toluene diisocyanate 74 43 Methylsilane triisocyanate (1-2 mol percent) Chloropolypropylene glycol (avg. mol. wt. 2000) 9.30 Octadecadienedioic acid 9.30 1,2,6 hexane triol 4.65 Water 2.32

RESIN 9 [Amine equivalent 500-600] 6-nitro 2-4 toluene diisocyanate 74 43 2,6 toluene diisocyanate (-90 mol percent) Amino ethanol Polypropyleneglycol (avg. mol. wt. 3000) 9.30

80-90 mol percent) Water 2.32 Triethanolamine 4.65 Ricinoleic acid 9 30 2-hydroxy malic acid (1-10 mol percent) RESIN 10 [Amine equivalent 400-500] 2,4 toluene diisocyanate 74.43 Polybutylene glycol (avg. mol. wt. 3000) 9.30 Ricinoleic acid I 9 30 Tartaric acid (1-5 mol percent) 1,2,6 hexanetriol 4 65 Diethylene trianiine (1-5 rnol percent) Water 2.32

1 Range 4-10 mol percent.

RESIN 11 [Amine equivalent 300-600] 2,4 toluene diisocyanate 74.43 Polypropylene glycol (avg. mol. wt. 5000) 1 9.30 'Ricinoleic acid 9.30 Water 2.32 1,2,6 hcxanetriol 4.65

1 Range 4-15 mol percent.

RESIN 12 [Amine equivalent 300-600] 2,4 toluene diisocyanate 74.43 Polybutylene glycol (avg. mol. wt. 2000) 1 9.30 Ricinoleic acid 9.30 Water 2.32 1,2,6 hexanetriol 4.65

1 Range 1-20 mol percent.

spam-ea '2 RESIN l3 [Amine equivalent 300-600] 2,4 toluene diisocyanate 74.43 Polyethylene glycol (avg. mol. wt. 1000) 1 9.30 Ricinoleic acid 9.30

Water 2.32 1,2,6 hexanetriol 4.65

1 Range 4'20 niol percent.

RESlN 14 [Amine equivalent 400-700l Meta toluene diisocyanate 74.43 Polypropyleie glycol (avg. mol. Wt. 4000) 1 9.30 Water 2.32 1,2,6 hexanetriol 4.65 Hydroxy propionic acid 9.30

1 Range 2-15 mol percent.

The average molecular weight of the polyglycols used in our above examples or formulations may range from 300 to 10,000 and is preferably between 1,000 and 5,000. Blends of polyglycols of different average molecular weights may also be employed eifectively in the resinous compositions. Polyethyleneglycols and polypropyleneglycols are commercially available in selected average molecular weights but containing factors or portions varying in molecular composition and it will usually be preferred to employ such commercial products although, of course, polyglycols each having a single molecular weight or a single range of molecular weights in their composition may be used individually or in blends as desired. Accordingly, where the expression average molecular Weight is employed in the above examples, it is intended to mean the average molecular weight of the polyethylene glycois or polypropylene glycols as commercially available and containing factors or portions varying in molecular composition although, as just noted, polyglycols each having a single molecular weight or a single range of molecular weights may, if desired, be em ployed in the preparation of the resins of the invention.

The following is a reaction chart for preparing a typical resin such as above described. The synthesizing of the resin should be carried out in a glass-lined reactor, 9. stainless steel reactor, or the like, and the temperatures, as well as the reaction times should be controlled. The time sequences, will, of course, vary with the size of the batch or run and the tailoring of the final resin to the desired or specified amine equivalent. The following chart covers the preparation of a pilot run in which approximately 1 gallon of the resin is produced, it being understood that the components referred to in the chart are merely illustrative of this type of resin.

Reticulating agent added. Reticulating agent addition compiste.

Reaction finished.

(cooling period) The resins of the invention represented by the above resins 1 to 14 inclusive, and their blends, are well suited as film forming and coating resins. We have found that thin layers of less than 1 mil and up to mils thickness are easily provided with these resins without the use of catalysts, oxygen, or drier activators. The resinous materials may be directly bladed onto a surface to provide thin films of the desired thickness, may be sprayed from a suitable solvent solution or may be brushed, dipped, calendered or spattered and, of course, may be applied to practically any material such as metal, wood, cloth, glass, plastic, etc. The adhesion of the resultant films to fabrics, wood and various porous and semiporous surfaces is excellent. Where the coatings are to be applied to smooth metal surfaces it is desirable to first apply a primer to obtain maximum adhesion. It has been found that coatings of the resins are relativley non-crazing to acrylic and styrene plastics and, therefore, are well suited for protecting these materials. The resins, when applied as above described, or when otherwise applied to form films or coatings, function as room temperature air cure coatings due to their structure which enables them to re act with the moisture of the air and thus polymerize into tough, resilient elastic coatings that are transparent or semi-transparent unless pigments or other modifiers are employed.

As already noted, the resins of the invention are suitable for use in the 100% solids resin content state as surface coating materials, film forming materials, etc. or may be employed in solvent-resin combinations. In the latter case the solvents serve primarily to control or facilitate application. It is preferred to employ polar solvents such as ketones, (primarily aliphatic), methyl ethyl ketone, methyl isobutyl ketone, acetone, and the like. It is desirable to employ solvents that have no labile hydrogen atoms capable of re-acting with the functional groups of the resinous compounds responsible for the curing of the films or coatings.

The resins are well suited for forming thin plastic films resembling cellophane, Saran, etc. and as impregnating resinous materials. When used to form plastic films the resins may be applied directly in thin films by means of rolls, by spraying, brushing, dipping, blading, or by similar procedures. The films air cure at room temperature absorbent or moisture sensitive materials, and lacor other surface to which they have been applied. The resins, when applied in a suitable manner, are also ef fective as protective coatin s for metals, wood, plastic, paper, etc. as impregnating materials for fabrics, screens, paper, and the like, as moisture-proof coatings for moisture absorbant or moisture sensitive materials, and lacquers, paints, primers, and the like, may be prerared or fabricated from the resins. When the resinous materials of the invention are to be employed in the manufacture of films or as impregnating materials, they may be suitably modified by the addition of plasticizers such. as dioctyl phthalate, dibutyl sebacate, tricresyl phosphate, and di 2- ethyl hexyl adipate and, of course, appropriate pigments may be incorporated such as graphite, carbon black, aluminum powder, and the like.

The modifiers for the resins such as the plasticizers and pigments may be milled directly into the resins if desired. The coating and film forming resins, with or without modification, cure by contact with the air at room temperature and at a relative humidity of from 20 to 98%, the resins polymerizing due to their reaction with the moisture in the atmosphere.

The following carriers, thinners, or solvents, may be used to obtain solutions of the resins of the invention of the desired consistencies:

Ketones, such as methyl ethyl l etone, di methyl ketone, methyl propyl ketone, and methyl isobutyl ketone;

Esters such as ethyl acetate, methyl propionate and amyl acetate;

Ethers such as ethyl arnyl ether, ethyl propyl ether, and 1,1 di chloro dipropyl ether; and

amass-a Alkyl or aryl halides such as trichloropropane, tetrachloro ethane and monochlorobenzene.

Each of resins 1 to 14 inclusive, employed individually or in suitable blends, are effective as coating compositions, impregnating compositions, plastic film forming compositions and for analogous purposes. A typical illustrative material may be prepared from resin 14 and methyl ethyl ltetone in a 90-l0% by weight blend respectively to constitute a suitable and eifective readily applied coating material. In such a material the methyl ethyl ketone may be replaced by acetone, ethylene dichloride or methyl propyl ketone. Where a loaded or pigmented product such as a coating material is desired, one of the resins and graphite, or other pigment, in a 90-10% by weight mixture is effective. The graphite may be replaced in whole or in part by carbon black, silica, or aluminum powder, and used with other resins. Resin 1, thinned with from 5 to 95% by weight of methyl ethyl ketone, or any of the other above described solvents or thinners, has been found to be eflective as a coating, impregnating material, etc. and any of resins 1 to 14 inclusive mixed with methyl ethyl ketone or other similar thinner or solvent are likewise efiective.

Where the resinous products of the invention are to be used as putties, sealants, caulking compounds, etc. or as the resinous ingredients of such putties, sealants, etc. it has been found most practical to utilize these resinous products with modifying resins. These modifying resins include or comprise polysulfide liquid polymers and are essentially reaction products derived from organic mono,

di and tri halides and sodium polysulfide, the polymer segments being linked together by sulphur bonds. The functional groups contain hydrogens which are reactive to the isocyanate radical and may consists of mercaptan groups such as terminal mercaptan groups, hydroxyl, carboxyl and amino groups. The poly-sulfide liquid polymers may also contain terminal alkyl, aryl and other non-functional groups provided there are at least two labile hydrogen containing groups per molecule to be reactive to the isocyanate. Side mercaptan groups may occur occasionally in the chain of the repeating units and some chain segments may be cross-linked at various points. .For reaction with sodium polysulfide, it is preferred to use dichloroethylformal or bis(2-chloroethylformal) as the organic dihalide although other dihalides such as ethylene dichloride, propylene dichloride, dichlorodiethyl ether and triglycol dichloride may be used alone or in mixtures to form copolymers. It is also preferred that these polysuliide liquid polymers be prepared with a small amount of a trifunctional halide such as trichloropropane, chloroform or trichloroethylene for cross-linking some of the chain segments. The polysultide liquid polymers may be prepared by reductive cleavage of the disulfide groups of the hi her molecular weight polymers to yield lower molecular weight products having thiol terminals. Thus the reaction of organic dihalide and sodium polysulfide yields a polymeric polysulfide:

Reductive cleavage of disulfide groups depolymerizes the molecules:

It is also possible to prepare such liquids of low molecular weight by employing a deficiency of sodium polysulfide (less than 1 mol of the polysullide to 1 mol of the dihalide). The liquid polysultide polymers from his (2- chloroethylformal) and sodium polysulfide all contain the repeating unit:

10 the terminals being thiol groups or These liquid polymers may be considered dimeric mercaptans. The polysullide resins suitable for incorporation in the sealants of the invention may be considered polymeric liquid polysulfides containing an average of at least two groups per molecule having isocyanate reactive hydrogens. The following is a typical preferred formulation for such a polysullide resin:

Polysulfide Resin M01 Percent Range Opt. Max.

dichloroethyl tormaL sodium tetrasulfide. trichloropropaue.

The sodium tetrasulfide may range from 25 to mol percent of the dichloroethyl formal.

The sodium polysuliide employed in the above formulation includes sodium tetrasulfide, sodium disulfide and like compounds represented by MaS where X is from 2 to 6 and Ma represents an alkali metal such as Na, K,

:Ce, Rb, or Li. The trichloropropane of the above general formulation for the preparation of polysulfide resins may be replaced by other trifunctional cross-linking halides such as carbon tetrachloride, tetrachloroethane, chloroform, etc. to form other series of useful representative polysulfide resins.

The commercial designations for the preferred polysulfide resins represented by the above general formula for such resins are: LP Series 2, 3, 8, 32, 33 and 38. The molecular weights and percentages of cross-linking of these LP. Thiokols are given in the following table:

Percent Gross- Linking Type M01. Wt.

d cree The following is a typical preferred formulation for the liquid polysulfide modifying resins:

Bis (Z-chloroethyl formal) 98. Trichloro propane 2. Sodium polysulfide (Na S (in which x=2-4.5) 60-120 mol percent of the formal.

Caulking materials, sealants and the like prepared from .liquid polysulfide polymers, previously described, are

found to be water sensitive to varying degrees. This water @sensitivity maybe ascribed to .the thiol groups present in the polysulfide molecule. On the other hand, it has been found difiicult to cast polyisocyanate resins in thick sections without the formation of voids. We have found that fluid resin reaction products of polyisocyanates, polyisothiocyanates and their blends, such as previously described, compounded with polymeric polysuliides containing an average of at least 2 labile hydrogen atoms per molecule, which are reactive to isoeyanates, suitably catalyzed, are effective as sealants, caulking materials, putties, etc. capable of being used or cast in thick sections without the formation of voids and are tough, rubbery, adherent, water and fuel resistant and retain their desirable physical characteristics at low temperatures. Thus, sealants, and the like, prepared from the derived polymers and copolymers of polyisocyanates, polyisothiocyanates, and their blends, and the polysulfide resins do not have the disadvantages of low water resistance, void formation, etc. above mentioned, but do possess the desirable characteristics of toughness, elasticity, low temperature flexibility, adherence, etc. The sealants of the invention possessing these physical characteristics are useful as tank sealants, aircraft cabin sealants, low temperature caulking materials, oil and grease gasketing materials, marine caulking materials, Window glazing materials, etc.

Sealants, caulking compounds and putties of the invention comprise compositions prepared from one or more of the liquid poiysulfides (Thiokols), one or more of the liquid polyisocyanate resins, and preferably a catalyst system for accelerating the cure. The desirable physical characteristics of the applied or resultant sealants resuit in part from the reaction of the labile hydrogens of the polysulfide resins With the free isocyanate or free isothiocyanate or blends of the polyisocyanate or isothiocyanate resins. Additional curing is effected by the action of atmospheric moisture on the isocyanate containing resin, acting as a chain lengthening and crosslinking agent by water which is released due to oxidation of the polysulfide mercaptan groups and by the formation of metallic mercaptides, the exact nature of the cure being, of course, a function of the particular sealant composition. We have found that sealants, caulking compounds, and the like, derived from the simple combination of the uncatalyzed liquid polysuh'ide resins and the uncatalyzed liquid polyisocyanate resins, both previously described, are slow setting, soft or semi-fluid, and only partially set. While such materials are adapted for specific uses or applications requiring ery soft sealants, it is usually preferred for most applications to employ sealants that cure more rapidly and that harden to a greater extent. We have provided catalyst means for controlling or accelerating the curing rate of the mixed polymers. It will usually be preferred to provide a catalyst or accelerator for each resin component of the sealant. Thus the catalyst for the polysulfide resin component may be mixed with the polyisocyanate resin to form a packagestable unit or material While the catalyst for the isocyanate polymer may be packaged in the polysuliide resin to likewise form a package-stable component. Subsequent mixing of these two units or components provides for the accelerated final cure of the blended polymers.

We have discovered dual or double catalyst systems for effectively controlling the reaction of these two types of resin components to produce satisfactory and reproducible final cure mechanisms and characteristics. The catalysts for the isocyanate class resins serve as activators for the peroxide catalysts for the polysulfide resin polymerization. Thus, it is a feature of the invention to provide dual acting catalysts used in various selected combinations with the blends or mixtures of anhydrous polyisoeyanate resins (and polyisothiocyanate-isocyanate resins) and anhydrous and nearly anhydrous polysulfide resins to produce void free sealants having the desirable physical characteristics of flexibility, resiliency, adherence, low temperature flexibility, etc.

The catalysts for the polyisocyanate type resins, that i2 is the catalysts that may or may not be initially mixed or packaged With the polysulfide resins are preferably heterocyclic nitrogen base compositions. The nitrogen base polyisocyanate catalysts are chosen so as to be compatible with the peroxides of the polysuiide catalysts. Typical of these preferred catalysts are: (l) Quinoline (2) ls ielamine (3) Morpholine (4) Methylmorpholine (5) 'ifhialdine (6) N-hydroxyethylmorpholine (7) N-hydroxybutylmorpholine (8) Pyridine (9) Triethylamiue (l0) Triethanol amine (ll) Tributyl amine (l2) Hydroxylarnine Mixtures or blends of these catalysts are useful in obtaining appropriate catalyst components. Blends with other nitrogen base compounds are also useable. The following are illustrative examples of blends or mixtures of the catalysts:

Catalyst 9 Percent by weight Triethanolarnine 50 Hydrazine 50 In this catalyst formulation the hydrazine may be employed in the proportion range of from 1 to 60% by weight, the balance being the triethanolamine.

Catalyst 10 Percent by weight Tributylamine 50 N-methylmorpholine 50 In catalyst 10 the N-rnethylmorpholine may be used in the proportion range of from 1 to 60% by weight, the balance being the tributylamine.

Catalyst 11 Percent by weight N-hydroxyethylrnorpholine 10 Tri-ethanolarnine In this formulation the N-hydroxyethylmorpholine may be employed in the proportion of from 1 to 15%, the balance being the triethanolarnine.

The catalyst or catalysts for the polyisocyanate type resins are employed in the proportion of from 5 to by weight of the total catalysts, the total weight of all of the catalysts being from 0.1 to 20% by weight of the total Sodium carbonate peroxide Magnesium peroxide Zinc peroxide Lead peroxide Calcium peroxide Sodium pyrophosphate peroxide Barium peroxide Sodium peroxide spa sa 13 The class C catalysts for the polysulfide resins are alkaline oxides and metals represented by:

Zinc oxide Cadmium oxide Mercury oxide The catalysts of classes A and B may, if desired, be used in conjunction with accelerators such as metal soaps, amines, or the fiollowing which are herein referred to as class D catalysts:

Diphenyl guanidine I-Iexarncthylene tetramiue Metal driers such as cobalt naphthenates and zinc octoate Zinc stearate Aluminum stearate Diphenyl guanidine phthalate P-quinone dioxine As above described, it may be preferred to incorporate the catalyst or catalyst blend for the polysulfide resin in the isocyanate resin component and to incorporate the catalyst or catalyst blend for the isocyanate type resin component in the polysulfide resin component.

Of course the several ingredients or components may be supplied individually and simply mixed together in an appropriate manner and in the selected or required proportions, the polyisocyanate type resin, or blends thereof being pre-prepared and the Thiokol or polysulfide resin likewise being pro-prepared.

Thus the tWo resin components may be prepared and packaged separately and if desired the two catalysts may likewise be each prepared and separately packaged, for mixing prior to use of the sealant. The catalysts, that is the total of the catalyst (dual) components preferably comprises from one-tenth to 20% by weight of the total resins. The catalyst system contains an activator or catalyst for each resin component in the proportion of at least by weight of the total catalyst with the possible addition of from 0.01 to to the selected polysulfide resin catalyst A, B or C of a rate control agent D. In this connection it may be noted that where a C class catalyst is employed it is desirable or important to also include a D type catalyst in the proportion of from at least 1% to not more than 50% of the total of catalysts C and D. The class A and class B catalysts may be used individually or may be used in blends in any selected ratios or, if desired, in combination with a D class catalyst where the D catalyst is employed in the amount of not more than 10% by weight of the catalyst mixture. The catalysts, that is the catalyst for the polyisocyanate or polyisothiocyanate-isocyanate resin component and the catalyst for the polysulfide resin are employed in the proportion of from to 20% by weight of the total resins.

The polysulfide resin component is employed in the proportion of from 5 to 95% by weight of the total weight of the resins and the polyisocyanate or polyisothiocyanate-isocyanate resin component is employed in the proportion of from 5 to 95% by weight of the total weight of the resins.

Suitable or appropriate modifiers such as fillers, coloring materials and plasticizers may be incorporated in the materials or products of the invention. The fillers or reinforcing agents that may be used include talc, mica, silica, asbestos, carbon black, rayon flock, mineral fillers, fibers, materials. The coloring ingredients may be or ganic dyes such as Sudan Red, Malachite Green, etc. or inorganic pigments such as the various iron oxides or the chrome yellows such as zinc chromate, lead chromate, etc. The plasticizers that may be included in the formulations in an amount up to 20% by weight of the total include chlorinated biphenyl resins containing from 10 to 30% chlorine, diesters such as dioctyl sebacate, esteramides, silicones, and diesters of polyglycols such as diethylene glycol dihexoate.

-Polysulfide resin L1 3 mol. wt. 1000, 60%

1. The following are typical preferred examples of the formulations for the sealants, caulking compounds, etc.

of the invention:

EXAMPLE 1 Percent Polysulfide resin LP2 mol. wt. 400, 25% Polysulfide resin L1 8 mol. wt. 300, 25% 98 Resin No. l, amine equivalent 400, 50% Tertiary butyl hydroperoxide, 50% 2 Catalyst No. 2, 50%

In Example 1, catalysts l, 3 or 4, or blends thereof, may be substituted for the catalyst 2.

EXAMPLE 2 Percent Polysulfide resin LP8 mol. wt. 300, 75% 95 Resin No. 2, amine equivalent 350, 25% Urea peroxide, 25% 5 Catalyst No. 5, 75%

In Example 2, catalysts 6, 7, 8, or blends of the same, may replace catalyst 5.

EXAMPLE 3 Percent Resin No. 4, amine equivalent 450, 40% 97 Lead peroxide, 30% 3 Catalyst No. 6, 70%

In Example 3, resins 5 or 7, or blends of the same, may replace resin 4.

EXAMPLE 4- Percent Polysulfide resin LP33, mol. wt. 1000, 40% 95 Resin No. 11, amine equivalent 500, 60% Sodium carbonate peroxide, 40% 5 Catalyst No. 4, 60%

In Example 4, resins 8, 9 or 10, or blends of the same, may replace resin 11.

EXAMPLE 5 Percent Polysulfide resin LPS, mol. wt. 4000, 15% Polysulfide resin LP38, mol. Wt. 300, 35% 98 /2 Resin No. 5, 50% Catalyst No. 7, 10% 11/2 Tertiary butylhydro peroxide,

In Example 5, catalyst 7 may be replaced by catalysts 8, 9 or 10.

EXAMPLE 6 Percent Polysulfide resin LP33, 60% Polysulfide resin LP8, 20%

Resin No. 7, 20% Cumene hydroperoxide, 5% 5 Catalyst No. 11, 95%

In this example, catalyst 11 may be replaced by catalyst EXAMPLE 7 Percent Polysulfide resin LP8, 20% Polysulfide resin LP32, 40% 90 Resin 9, 60% Tertiary butyl perbenzoate, 80% 1O Catalyst No. 15, 20%

In Example 7, catalyst 15 may be replaced by catalyst 16 or 17.

which we have expressed. Nor is the invention to be regarded as limited to the express procedures or materials set forth, these details being given only by Way of illustration and to aid in clarifying the invention. We do not regard such specific details as essential to the invention except insofar as they are expressed by way of limitation in the following clair s wherein it is our intention to claim all novelty inherent in the invention as broadly as permissible in View of the prior art.

We claim:

1. The resinous material which is the product of reaction on an approximate mol percentage basis of, from 2.5 to 23.5% of a dinydric alcohol selected from the group consisting of 1,4 butane diol, 2 methyl butane diol, 1,4 hexane diol, 1,3 propylene glycol, butyne diol, and polypropyle e glycol having a molecular weight range or" 400 to 10,000, from 64.5 to 84.5% of a polyisocyanate of the general formula selected from the group consisting or:

in which R is an intervening organic group, the dihydric alcohol and the diisocyanate reacting to form a first intermediate, from 2.5 to 23.5% of a bifunctional acid selected from the group consisting of malonic acid, succinic acid, sebacic, adipic, pimelic, azelaic, hydroxypropionic, l-hydroxy decanoic acid, ricinoleic acid and glycolic acid, and from 0.59 to 8.7% water, said bifunctional acid and Water being reacted with said first intermediate to form a second intermediate, and from 1.08 to 16.3% of a polyhydric alcohol having more than 20H groups per molecule reacted with said second intermediate to form an intermediate reaction product, a catalyst selected from the group consisting of quinoline, melamine, morpholine, methyl morpholine, thialdine, N-hydroxy ethylmorpholine, N-hydroxy butylmorpholine, pyridine, trietnylamine, triethanolamine, tributylaminc, and hydroxylamine for said intermediate reaction product, a polysuliide liquid polymer having a molecular weight of from 200 to 10,000 and which is the reaction product of a sodium polysulfide and an orcanic dihalo compound selected from the group consisting of 2,2 dichloro diethylether, triethylene glycol dichloride, dichlorodiethylformal, dichloropolyethylene glycol, dichloropolypropylene glycol, dichlorodiethylacetal, dichlorobutane, clichlorcdiethyllcctone and glycerol dichlorohydrin and which contains at least 2 labile hydrogen containing groups per molecule, and a catalyst for said polysulfide liquid polymer selected from the group consisting of tertiary butylhydrcperoxide, cumenehydroperoxide, ureaperoxide, acetylperoxide, di-ter-butylperoxide, l-hydroxy cyclo-hexylhydroperoxide, t-butylperbenzoate, sodium carbonate peroxide, magnesium peroxide, zinc peroxide, lead peroxide, calcium peroxide, sodium pyrophosphate peroxide, barium peroxide, sodium peroxide, zinc oxide, cadmium oxide and mercury oxide, said total of said catalyst components comprising from .1 to 20% by weight of the total resins, said polysuliidc liquid polymer and said catalysts for said polysuliide liquid polymer being added to said intermediate reaction product and said catalysts for said intermediate reaction product to react and form the resinous material.

2. A sealant prepared on an approximate percentage by weight basis, from 5 to 95% of a poly sulfide liquid polymer having at least two labile hydrogen containing groups per molecule and containing the repeating unit (SSCl-l Cl-l OC-i OCH CH and having a molecular weight of from 200 to 10,000 and which is the reaction product of a sodium polysultide and an organic dihalo compound selected from the group consisting of 2,2 dicl'ilorodiethylether, triethylene glycol dichloride, dichlorodiethyliormal, dichloropolycthylene glycol, dichloropclypropylene glycol, dichlorodiethylacetal, diehlorobutane, dichlorodiethyllzetone and glycerol dichlorohydrin, from 5 to 95% of an isocyanate resin which is the reaction product of on an approximate mol percentage oasis from 2.5 to 23.5% of a dihydric alcohol selected from the group consisting of 1,4 butane diol, 2 methyl butane diol, 1,4 hexane diol, 1,3 propylene glycol, butyne diol, and polypropylene glycol having a molecular weight range of from 400 to 10,000, from 64.5 to 84.5% of a polyisocyanate of the general formula selected from the group consisting of:

in which R is an intervening group, the dihydric alcohol and the diisocyanate reacting to form a first intermediate, from 2.5 to 23.5% of a bifunctional acid se lected from the group consisting of malonic acid, succinic acid, sebacic, adipic, pimelic, azelaic, hydroxypropicnic, l-hydroxydecanoic acid, ricinoleic acid and glycoiic acid, and from 0.59 to 8.7% water, said bitunctional acid and water being reacted with said first intermediate to form a second intermediate, and from 1.08 to 16.3% of a polyhydric alcohol having more than two OH groups per molecule reacted with said second intermediate polymer to form a resinous material, and from 0.1 to 20% of a catalyst, said catalyst including from 5 to 95% by weight of the total catalyst of an organic peroxide for accelerating cure of said polysulfide polymer and selected from the group consisting of tertiary butyl hydroperoxide, cumene hydroperoxide, ureaperoxide, acetylperoxide, di-ter-butylperoxide, 1 hydroxy cyclohexylhydroperoxide, t-butylperbenzoate, sodium carbonate peroxide, magnesium peroxide, zinc peroxide, lead peroxide, calcium peroxide, sodium pyrophosphate peroxide, barium peroxide, sodium peroxide, zinc oxide, cadmium oxide and mercury oxide, and from 5 to 95% by weight of the total catalyst of a heterocyclic nitrogen base composition for accelerating the cure of said isocyanate resin, said nitrogen base composition being compatible with said organic peroxide and being selected from the group consisting of quinoline, melamine, morpholine, methylrnorpholine, thialdine, N-hydroxy ethylmorpholine, N-hydroxy butylmorpholine, pyridine, triethylamine, triethanolarnine, tributylamine, and hydroxylamine, said polysuli'lde polymer and polysulfide polymer catalyst being reacted with said isocyanate resin and isocyanate resin catalyst to form said sealant.

References Jilted in the file of this patent UNETED STATES PATENTS 2,466,963 l-atrick et a1. M Apr. 12, 1949 2,894,919 Simon et al. July 14, 1959 2,943,691 Windemuth et a1 Aug. 9, 1960 

1. THE RESINOUS MATERIAL WHICH IS THE PRODUCT OF REACTION ON AN APPROXIMATE MOL PERCENTAGE BASIS OF, FROM 2.5 TO 23.5% OF A DIHYDRIC ALCOHOL SELECTED FROM THE GROUP CONSISTING OF 1,4 BUTANE DIOL, 2 METHYL BUTANE DIOL, 1,4 HEXANE DIOL, 1,3 PROPYLENE GLYCOL, BUTYNE DIOL, AND POLYPROPYLENE GLYCOL HAVING A MOLECULAR WEIGHT RANGE OF 400 TO 10,000, FROM 64.5 TO 84.5% OF A POLYISOCYANATE OF THE GENERAL FORMULA SELECTED FROM THE GROUP CONSISTING OF: 